ECU OPEL GT-R 1973 User Guide

ll- 66 1973 OPEL SERVICE MANUALi
ConditionPossible CauseCorrection
Gas gauge does not read
full when tank tilled1. Tank unit misadjusted1. Install 40 ohm resistor
between connector and ground
I
(disconnect from unit). If
dash unit reads full within
one pointer width. Remove
/
Igas tank unit from tank, install
connector, ground unit and
adjust tab to obtairi full reading on
dash. Reinstall tank unit.
2. Defective’ voltage
stabilizer1. See corrective action above.
Gas gauge not operating1. Corroded tank unit
terminal I1. Check tank unit terminal, if
corroded clean, pack connector
with grease and reinstall
connector..
2. Loose dash gauge
!
1. Install 40 ohm resistor between
sending unit connector. and
ground (disconnect from tank
terminal). If dashgauge does
not read rull, check dash gauge
attaching nuts for secureness
and tighten if required.
(Requires removal of dash panel)
Momentarily touch dash gauge
attaching studs to 12 volt
source. If indicator moves,
reinstall panel; if not, replace
gauge. (Caution do not keep
studs connected to 12 volt
source for more than a few
seconds
- damage to gauge can
result)
3. Open
w&g1. Remove connector from sending
unit and ground (40 ohm
resistor may be used if
ohmmeter available. Remove
multiple connector from rear
of dash. Connect test light
to ground and touch other end
to connector socket with blue
and black wire, if it does not
light (40 ohm reading of ohm
meter used) repair open circuit.
4. Defective gas tank
sending unit1. Install 40 ohm resistor between
temperature sending unit and
ground (disconnect from unit)
if dash unit reads full scale.
Replace tank unit (check for
terminal corrosion before
replacing).

I
GAUGES1 I- 67I
I Condition
Car
&s out of gas with
gauge indicating fuel in
tank. 1
I
I
I
I
IPossible Cause
1. Tank unit misadjusted
2. Defective voltage
stabilizer.Correction
1. Follow corrective action as
stated above (obtain empty
reading on dash)
1. See corrective action above.
Temperature gauge not1. Loose dash gauge1. See corrective action above.
Iattaching nut.
I
I
I2. Defective temperature1. Install 40 ohm resistor
Isending unitbetween temperature sneding
Iunit and ground (disconnect
I
from unit). If dash unit reads
I
full scale, replace temperature
Isending unit.
I
I
I3. Open wiring.1. Follow corrective action as
Istated above (connector socket
Iwith blue wire).Tempkrature gauge indicates
hot when engine temperature1. Incorrect temperature1. Check for correct sending unit
sending unit
normal.(white porcelain) replace if
incorrect.
2. i>efective temperaturesending unit.1. See corrective action above.
3. Dkfective voltage
stabilizer.
1. See Corrective action above.
GAS
GdUGE TROUBLE DIAGNOSIS - GT4. Disconnect the tank unit lead wire (light blue with
black tracer) from the tank unit.
An inoperative gas gauge reading can normally be
found to result from a poor grounding condition
within the circuit. Using the procedure as outlined
below may lead to the correction of the inoperative
reading without replacement of either the tank unit
or the
dph unit.5. Connect ihe stock tank unit; ground unit, and
operate manually.
6. If the dash unit shows a correct reading, then
replacement of the tank unit is required as the cor-
rection.
1. Makelcertain the gas tank (ground) strap is prop-
erly secured.A correct reading will be one which resembles the
movement of the manually-operated tank unit.
2. Make’certain the ground wire (brown in color) for
gasoline/ and temperature gauges is properly con-
nected tb the windshield wiper motor and is secured.
(This
gl?ound wire is also common for the heater
blower
etor.)7. If the dash unit does not show a correct reading,
then its replacement is necessary.
If the adove procedure does not produce a satisfac-
tory gaube reading, an attempt to isolate the defec-
tive
par<, i.e. tank or dash unit should be made.
3. Rem&e a tank unit from parts stock.MAJOR
AEPAIR
OPEL 1900. MANTA
Removing Voltage Stabilizer1. Remove instrument cluster housing assembly.

2C- 121973 OPEL SERVICE MANUAL
3. Install quarter window and fasten chromed mold-
ing. See Figure 2C-10.REMOVAL AND INSTALLATION OF REAR
QUARTER WINDOW OPEL 1900. MANTA
1. Unscrew rear quarter window
Iqck. See Figure2c-11.
Figure
2C-1 1 Quarter Window Lock Attaching Screws
2. Unscrew window hinge from lock pillar while
holding window. See Figure
2C-12.3. On installation, seal hinges with a plastic com-
pound.
Figure 2C-12
Cluarter Window Hinge AttachingSCW@S4. Carefully push rail off window. On rear quarter
window lock, drill off pin and unscrew retainer from
window. See Figure
2C-13.Figure 2C-13 Drilling Off Quarter Window Lock Pin
REMOVAL AND INSTALLATION OF HINGED
REAR QUARTER WINDOW
- GT
Removal1. Remove three screws securing lock to rear quarter
pillar. See Figure
2C-14. Swing window outward and
lift off rear quarter window. Care should betaken
that window does not fall off pivots when swung
outward.
Figure 2C-14 Rear Quarter Pillar Lock
- GT
2. Remove frame from glass
Installation1. Install frame to glass.
2. Install lock to rear quarter pillar, securing with
three (3) screws.

2D-161973 OPEL SERVICE MANUAL
2. Remove door lock knob.
3. Remove door inside handle.
4. Adjust sash window so that the main lever with
toothed segment are in alignment with the front re-
taining plate. See Figure 2D-9.Figure 2D-9 Aligning Main Lever With Front Retaining
Plate5. On Models 57, 57L and 57R, scribe position of
screw at the plastic support of window rail and un-SCRW.
6. Block sash window in door interior.
7. Scribe position of window lifter guide rail
screws.See Figure 2D- 10.
Figure 2D-10 Guide Rail Screws
8. Unscrew window lifter and let it down slowly.
9. Slide window upwards and block it.10. Remove window lifter through opening in inner
door panel upper part. See Figure 2D-11.
Figure
2D-1 1 Removing Window Lifter
Installation
1. Install window lifter through opening in inner
door panel tipper part. See Figure 2D-
11.2. Block window upwards.
3. Secure window lifter.
4. On Models 57 and 57R, secure plastic support of
window rail.
5. Install inside door handle.
6. Install door lock knob.
7. Install door trim pad.
REMOVAL AND INSTALLATION OF FRONT DOOR
LOCKRemoval
1. Remove door trim pad.
2. Remove door lock knob.
3. Remove door inside handle.
4. On lock side, scribe position of guide rail bolt,
unscrew bolt, push guide rail downwards, and
remove it through access hole. See Figure 2D-12.
5. Remove door lock and install new one. See Figure
2D-13.

DOORSZD- 21
RIGHTLEFT ~-ZD-27
Figure ZD-27 Cables Wound On Regulators
Installation - Right DoorIn clockwise direction, wind cable onto pulley up to
the shoulder and clamp it behind lug. See Figure2D-27.
REMOVING AND INSTALLING
’
TAILGATE HINGES
Removal1. Remove screws securing hinge trim panel covering
tailgate binges and lift out trim panel. See Figure
2D-28.2. Disconnect battery, remove tail
te trun pad, and
withdraw wiring from tailgate.
u3. Mark position of tailgate hinges on tailgate,
remove bolts securing tailgate to hinges and lift off
tailgate.
,’HINGE TRIM
PANEL1IFigure ZD-28 Removing Tailgate Hinge Trim Panel
4. Release and remove torque rods. See Figure 2D-
29.Figure ZD-29 Tailgate Torque Rods
5. Remove bolts securing tailgate hinges to roof
panel and lift out tailgate hinges.
Installation1. Install tailgate hinges to roof panel and secure
with bolts.
2. Install torque rods. Installation of torque rods may
be facilitated by using vise-grip pliers to work torque
rod end over catch.
3. Install tailgate to tailgate hinges.
4. Install wiring to tailgate
5. Install tailgate trim pad and tailgate hinges panel
COVehg.6. Connect battery

2F-261973 OPEL SERVICE MANUALMAINTENANCE AND ADJUSTMENTSADJUSTING HEIGHT OF SUN ROOF PANEL
Adjust height of sun roof as follows:
1. Opel sun roof to half open position and pry apart
sun roof frame from sun roof panel (see Figure
2F-1).Figure
ZF-1 Separating Sun Roof Frame From SunRoof Panel2. Push detached sun roof frame rearward until it
contacts car roof stop.
NOTE: If difficulty is encountered when pushing
sun roof frame to rear due to the frame hooking into
the sun roof panel, close sun roof until lifters come
into operation. The sun roof frame should now easily
slide rearward.
ADJUSTMENT FRONT OF SUN ROOF
To adjust height of front of sun roof proceed as
follows:
1. Close sun roof.
2. Loosen screws securing front guides to front of sun
roof panel (see Figure
2F-2). Rotate height adjust-
ment ring until desired height is attained.
3. Readjust guides outward so that guides just touch
sides of rails and are not wedged or cocked against
rail sides and tighten screws. Recheck height adjust-
ment.
NOTE: The guides should lightly contact the guideFigure
ZF-2 Sun Roof Front Guide
rail and should have a clearance of no more than 0.02
inch.
ADJUSTMENT. REAR OF SUN ROOF
To adjust height of rear of sun roof proceed as fol-
lows:1. Completely close sun roof and check that the rear
sun roof lifter guides from approximately a 90 degree
angle with respect to the guide rail and that the lifter
contacts the guide stop (see Figure
2F-3). If this is
Figure
2F-3 Rear Sun Roof Lifter 90 Degrees toGuide Rail

2F-281973 OPEL SERVICE MANUAL
guides to height adjustment rings, loosen second
screw (see Figure 2F-6), and swing guides away from
guide rail.
NOTE: When swinging front guides inboard, be
careful not to change position of height adjustment
rings. It is suggested that the position of the height
adjustment rings be marked with a pencil prior to
loosening of front guide attaching screws.
5. Retighten remaining screw holding front guide in
position to prevent height adjustment rings from
turning.
6. Turn lifter guide tension springs 90 degrees in-
board and pull lifters out of sun roof panel brackets
(see Figure
2F-7).Figure
ZF-7 Pulling Rear Lifter Guide out of Sun RoofPanel BracketNOTE: Do not loosen lifter pin nut as this will
change height adjustment on rear of sun roof.
7. Lift out sun roof panel.
Installation of Sun Roof Panel1. Install sun roof panel onto guide rails and locate
panel evenly in stin roof opening.
2. Reposition front guides in original position on
guide rails. Be sure that they squarely contact guide
rails and are not cocked.
NOTE: To achieve proper clearance of front guides
to guide rail, the guides should lightly touch edge ofdshould have a clearance of no
3. Reconnect
riar lifter guides onto sun roof panel
brackets and reposition tension spring as shown in
Figure
2F-3.4. Crank sun roof fully closed and check that the rear
lifters are at approximately 90 degrees with respect
to guide rails and contact guide stops (see Figure
2F-3). If adjustment is required remove crank handle
and cable crank (see Figure 2F-4) and physically
reposition lifters to position described above. Rotate
cable crank to its fully clockwise limit and reinstall.
5. Pull sun roof frame forward and reattach to sun
roof panel.
6. Open and close sun roof several times and recheck
for smoothness of operation.
Removal of Sunlpoof Frame1. Remove sun roof panel.
2. Crank rear lifter guides to furthermost rear posi-
tion.
3. Remove screws securing upper corner plates in
position and lift out upper corner plates (see Figure
2F-8).Figure 2F-&Removing Upper Corner Plates
4. Remove scretii securing left und
r@t guide rai1%lift up front ends
of- guide rails and msert wedge
under forward g&de rail ends. Slide out sun roof
frame.

ROOF AND SUN ROOF2F-29Installation of Sun Roof Frame1. Slide sun roof frame into lower slot of guide rails,
position fully rearward and reattach guide rails to
roof.NOTE: Be sure guide rail retainers at rear of guide
rails are positioned with their dowels in bores of roof
frame.2. Install upper corner plates and secure in place..
3. Install sun roof panel.
REMOVAL AND INSTALLATION OF VELVET STRIP
ON SUN ROOF OPENING, AND VELVET STRIP AND
WEATHERSTRIP ON REAR OF SUN ROOF PANEL
Removal of Velvet Strip on Sun Roof Opening1. Fully open sun roof.
;2. Carefully pull off velvet strip using solvent to dis-
solve cement. Clean area thoroughly before installing
new velvet strip.
Installation of Velvet Strip On Sun Roof Opening1. Cut away for a distance of 1.5 inch the velvet
material on velvet strip that will be on the outside
when strip is cemented in positioAlso cut off to
this dimension the plastic cord i
not cut away velvet material on
1strip which is to be cemented
2. Using
nitrile vinyl trim adhesive (3M Vinyl Trim
Adhesive, Permalastic Viny1 Trim Adhesive or
equivalent) apply sparingly to both sun roof opening
and side of velvet strip to be cemented.
3. Immediately install new velvet strip and position
so that upper edge of velvet strip is flush with car
roof.4. Clean off excess cement being careful not to con-
tact velvet strip.
Removal of Velvet Strip and Wea’therstrip on Rear
of Sun Roof Panel1. Remove sun roof panel.
2. Carefully detach weatherstrip and velvet strip
from sun roof panel using solvent as required todisdolve cement. Thoroughly clean area before in-
stalling new velvet strip and weatherstrip.
Installing Velvet Strip and Weatherstrip On Rear
of Sun Roof Panel1. Using
nitrile vinyl trim adhesive (3M Vinyl Trim
Adhesive Permalastic Viny1 Trim Adhesive or
equivalent) apply sparingly to vertical and horizontal
contact areas at rear of sun roof panel (see Figure
2F-9) and also to side of velvet strip which will touch sun
roof panel.
REAR OF SUN ROOF PANEL
ICAR ROOF
VELVET STRIP
II
,/ WETRSTRIP 1APPLY CEMENT TO HORIZONTAL AND
VERTICAL SURFACES,TO BOTH SIDES
OF VELVET STRIP AND TO SIDE AND
BOTTOM OF WEATHERSTRIP2F-9
Figure
ZF-9 Installing Velvet Strip and Weatherstrip
on Rear of Sun Roof Panel
2. Immediately install new velvet strip and position
so that top edge of velvet strip is flush with sun roof
panel.
3. Apply cement to outboard edge of velvet strip and
to top and bottom contact surfaces of weatherstrip,
and install weatherstrip in position.
4. Clean off excess cement being careful not to con-
tact velvet strip.
5. Install sun roof panel.
REMOVAL AND INSTALLATION OF REAR GUIDES
AND CABLE
Removal of Rear Guides and Cable
1. Remove sun roof panel.
2. Crank rear lifter guides fully rearward and then
remove crank handle and cable crank.

2F-321973 OPEL SERVICE MANUAL
3. Carefully detach a portion of headlining around
window corner post involved.
4. Detach water drain hose from sun roof hose iit-
ting.
5. Remove cowl side kickpads.
6. Pull out from upper end front water drain hose.
Installation of Front Water Drain Hose
1. Insert from above water drain hose (wider end
upward) into door hinge pillar.
NOTE: Do not mistake front and rear water hoses.
The front hose is thinner than the rear hose and is
wider at the end which connects to hose fitting on
sun roof. The rear hose is uniform over its entire
length.
2. Work water drain hose downward through lower
half of door hinge pillar and be sure hose terminates
behind door sill flange at bottom of frbnt fender.
3. Cement upper portion of water drain hose to sun
roof hose fitting.
4. Cement detached portions of headlining into place
by use of rubber cement or nitrile vinyl trim adhesive
(3M Vinyl Trim Adhesive, Permalastic Vinyl Trim
Adhesive or equivalent).
5. Complete installation reverse of removal proce-
dures.
Removal of Rear Water Drain Hose1. Remove rear seat and rear seat back.2. Pry out plastic fasteners securing cardboard parcel
shelf in position and remove shelf.
3. Remove rear quarter trim pad.
4. Detach headlining only as required from area
around rear window pillar.
5. Pull out rear water drain hose.
Installation of Rear Water Drain Hose1. Install rear water drain hose in original position.
Insert hose from above and work downward. Ce-
ment both ends of hose in place.
2. Secure water drain hose in place along wheel-
house.3. Complete installation reverse of removal proce-
dures.
REMOVAL AND INSTALLATION
OF LUGGAGE
RACKAll 1973 luggage racks will be dealer installed, and
are held to the roof at the 4 corners. Removal and
installation is accomplished by removing the attach-
ing screw at each corner. See Figure
2F-14.Figure ZF-14 Luggage Rack

SEATS, INTERIOR TRIM AND HEADLININGZG-35
2. Push off side panel trim pad. Trim pad is held in
position by a retaining button.
REMOVAL AND INSTALLATIONOF HEADLINING
Removal
1. Disconnect battery.
2. Lift out rear seat cushion (sedans only).
3. From trunk area, loosen tabs holding cardboard
against rear seat cross brace and lift out cardboard
(sedans only).
4. Pry up two tabs holding lower portion of rear seat
back in position, swing back of seat forward and lift
out (sedans only).
5. From trunk area pry out parcel shelf plastic retain-
ers and lift out parcel shelf (sedans only).
6. Remove rear-view mirror, sun visors, interior
lamp, assist straps and coat hooks. Remove front and
rear windows on all but Wagon Models. On Wagons,
remove the front window and the quarter windows.
7. Work door opening pinchweld finishing strip
away from pinchweld as far as necessary to expose
edge of headlining.
8. Start at: left or right windshield pillar and pry
headlining loose.
9. Roll back headlining to expose metal tabs securing
headlining listing wire to roof and unhook headhn-
ing front listing wire from metal tabs using a blunt
edge tool.
10. Pull loose the edges of headlining cemented to
door openings, rear quarter window openings, rear
quarter pillar and from under rear window rubber
channel. On rear quarter pillars, slightly bend down
cardboard of rear quarter trim pad to facilitate re-
moval. During removal, special care should be taken
not to tear headlining at seams.
11. After edges of headlining have been pulled loose,
tilt remaining listing wires with headlining forward
or rearward and pull listing wires free from side roof
rails. Lift out headlining and listing wires.
Installation1. Check secureness of noise insulation pad on inside
of roof panel and recement as necessary using asphalt
cement. If headlining is to be replaced, insert listing
wires into headlining according to their markings.
Progressing from the front listing wire to the rear
wire, the left ends of the wires are color coded as
follows:1st listing wire
- No marking, wire is thinner than
other wires
2nd listing wire
- Red
3rd listing wire
- Blue
4th listing wire
_ Green
5th listing wire
- Brown
6th listing wire
- White
2. Install 1st listing wire ends into retainer slots in-
side roof rails and hook listing wire into six metal
tabs above windshield. Lightly bend tabs with a ham-
mer as shown in Figure
2G-8.
HEAOLlN’lNdA-----
26-8Figure
2G-8 Headlining With 1st Listing Wire Hooked
Onto Metal Tabs
LISTINGWIRE
SECTIOND-D
4 26-9Figure 2G-9 2nd and 5th Listing Wire Attachment